Measurement System Analysis For Automated Test Systems

Dave Barnard Bob Trinnes Rockwell Automation, Inc

Why ? .

Measurement System Studies How much of my tolerance is being used up by my measurement system? Can I tell a good part from a bad part? .

Measurement System Studies Measurement Error Accuracy Instrument traceability to standards Precision Repeatability Same person Same machine Same setup Reproducibility Different person Different machine Different setup .

Repeatability is the variation between the measurements obtained when an operator measures the same dimension (characteristic) several times under the following conditions: • the same measuring instrument. . Note that the measurements may show good repeatability without being accurate. • on the same parts. • in the same location on the part. The repeatability error comes from the instrument itself and the position of the part in relation to the instrument. • under the same conditions of use.Measurement System Studies Repeatability: Repeatability is the spacing (dispersion) between measurements. Repeatability Repeatability is considered to be the inherent variation of the measurement system. • over a short period of time.

• the same method. • over a short period of time. . • in the same location on the part. • under the same conditions of use.Measurement System Studies MEASUREMENT SYSTEM Reproducibility: Reproducibility is the variation between the mean measurements obtained by different operators who Operator B measure the same dimension (characteristic) on the same parts under the following Operator A conditions: • the same measuring Reproducibility instrument.

• overvaluing or undervaluing process capability. • no corrective actions. . Important issues are at stake in a measurement systems analysis. • accepting defective products. • taking corrective action on false problems. An inadequate measurement system could have the following impact. • identifying the wrong causes of process variation. • rejecting conforming products. • concealing certain process variations.Measurement System Studies MEASUREMENT SYSTEM ANALYSIS: (Gauge R&R STUDY) The objective of the measurement systems analysis is to obtain information concerning the scope and type of error that the measurement system produces when it interacts with its environment.

Measurement System Studies Capability Study (CPK) vs Measurement Systems Study Measured values Differences In Measured Values Required Tolerance Range Required Tolerance Range .

Measurement System Studies 3070 Tester Studies Reproducibility Setup 1 Modules 1 2 3 4 5 6 7 8 9 10 Trial 1 Trial 2 Trial 3 Trial 1 Setup 2 Trial 2 Trial 3 Repeatability .

Measurement System Studies Simplified Explanation of Analysis Differences in measurement from repeats Part Tolerance = % tolerance used by repeatability Differences in measurement from reproduction Part Of measurements Tolerance = % tolerance used by reproduciibility All measurement differences Part Tolerance = % tolerance used by measurement system (total gauge R & R) .

71 34% 0.Greater than 29% is unacceptable and requires corrective action .20 Total Gauge R & R % of Tolerance R&R Used by Measurement Variation 6.will be yellow .30 0.00 0% Attribute Data Gauge R & R Results Attribute Repeatability Results Fail Attribute Reproducibility Results Fail Rbar1 2.Less that 10% is ideal and will highlight the cell in green .71 34% .Measurement System Studies Output Of Study Variable Data Gauge R & R Results Repeatability Reproducibility % of % of Tolerance Tolerance Used By Rbar2 UCLR EV AV Used By Repeatability Reproducibility Error Error 5.66 6.11% to 29% is cautionary but may be acceptable depending on the criticalness of the check .will be red .

SO? • The Jumper ‘Issue’ – Threshold tests • Fixture PMs – 75% of issues traced here • Analog tolerance settings • Capability Analysis tool .

Questions .